Feed-through seal for a high-power laser fiber optic cable

ABSTRACT

A lasing system for forming a sealed barrier between a process environment and an environment external to the process environment. The lasing system includes a wall enclosing the process environment. The lasing system also includes a laser connector coupled to the wall and a line. It should also be added that in one exemplary embodiment, the laser connector is configured to be releasably coupled to the wall and the line. The line, such as for example a fiber optic line, provides the lasing system with laser energy from a high-powered laser. In one exemplary embodiment, the energy from the laser is between 100 to about 1000 watts. Operatively, the wall and the laser connector form an environmental barrier between the process environment and the outside environment.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.09/909,606 filed Jul. 20, 2001 now U.S. Pat. No. 6,597,855 entitled,“FEED-THROUGH SEAL FOR A HIGH-POWER LASER FIBER OPTIC CABLE”, by BrianT. Rosenberger and William M. Carra.

BACKGROUND OF THE INVENTION

The present invention generally relates to a system and method fordirecting high-powered laser energy through a connector unit for usewithin a process environment. More particularly, this invention relatesto a system and method for establishing an environmental barrier betweenthe process environment and the outside environment from which the laserenergy is received therefrom.

DESCRIPTION OF THE RELATED ART

Today, many typical industrial applications of high-powered lasersimplement an open beam laser for a process operation. For example, inwelding applications, open beam lasers are used to join componentstogether. In these industrial settings, however, open beam cutting canpose a potential danger to nearby personnel by exposing them to harmfulvapors and residual debris arising from the open beam cutting process.Moreover, the task of re-directing open beam lasers is tedious as wellas hazardous. Typically, open beam laser beams are ultimatelyre-directed toward a process operation according to the meticulousplacement of mirrors. A misguided beam could damage the processoperation in which the beam is applied to. For example, a misguided beamcould damage component parts to be welded and possibly injure nearbypersonnel.

In terms of cost and safety issues, the application of open beam lasersis not acceptable. In the attempt to address these issues, somehigh-powered lasers are provided through a closed beam arrangement. Atypical closed beam arrangement involves providing a beam through alarge rigid protective shelter, such as an opaque tube. Due to the rigidnature of the enclosing, although providing limited safety byrestricting objects from passing through the beam, re-directing a closedlaser beam toward a desired application is difficult.

Currently, in terms of safety, there is a growing trend to providehigh-powered laser beams through a fiber optic line. Fiber optic linesredirect a passing beam with negligible loss in fidelity, thus allowingthe lines to transfer a high-powered laser beam through them.

The task of introducing laser beams into a closed environment, such asfor example a vacuum chamber, a pressure vessel, or a closed chamber toisolate hazardous material, is not typically provided in high-poweredlaser applications. Accordingly, the laser industry does not currentlyprovide a coupling arrangement to transfer high-powered laser energiesfrom a fiber optic-line to an application within a closed environmentwhile maintaining the environmental integrity of that closedenvironment. Moreover, most typical connector arrangements are not costeffective, replaceable or easy to use. This is especially true for thosethat feed laser energies from a high-powered line into a processenvironment. Many other problems and disadvantages of the prior art willbecome apparent to one skilled in the art after comparing such prioritywith the present invention as described herein.

BRIEF SUMMARY OF THE INVENTION

Aspects of the invention are found in a lasing system that receiveshigh-powered laser energy from a line. The lasing system forms a sealedbarrier between a process environment and an environment external to theprocess environment. In one aspect, a wall encloses the processenvironment and provides an environmental barrier from the outsideenvironment. In another aspect, a sealer isolates the processenvironment to an external environment. In another aspect, a processoperation, located within the process environment, performs a functionusing the received laser energy. In one exemplary embodiment, laserenergy that is transmitted through a line and received by a processoperation is in the range between 100 to about 1000 watts.Illustratively, a process operation may include a welding operationwhere laser energy is used to join components together. Additionally,among other functions, a process operation may include testing themechanical characteristics of a system, such as for example strength andfracture characteristics, using laser energy.

In a further aspect, a laser connector is releasably coupled to the lineand to the wall. As such, various aspects of the invention may quicklyand effortlessly be repaired or replaced in a cost effective manner.

Other aspects, advantages, and novel features of the present inventionwill become apparent from the detailed description of the invention whenconsidered in conjunction with the accompanying drawings. Many otherbeneficial results can be attained by applying the disclosed inventionin a different manner or modifying the invention as will be described.Accordingly, a fuller understanding of the invention may be had byreferring to the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and theadvantages thereof, reference should be made to the following DetailedDescription taken in connection with the accompanying drawings in which:

FIG. 1 is a schematic diagram of a lasing system according to theinvention.

FIG. 2 is a schematic diagram detailing exemplary aspects of the lasingsystem of the invention.

FIG. 3 is a schematic diagram of another embodiment of the lasing systemof the invention of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 is an exemplary schematic diagram of a lasing system, accordingto the invention. A lasing system 15 receives high-powered laser energy35 from a line 30. The lasing energy 35 is transmitted across the line30 to a laser connection unit 40. The laser connection unit 40 iscoupled to the line 30 and to a wall 21.

The line 30 may be any suitable optical medium for the transmission ofhigh-powered laser energy 35. Illustrative examples for such a line mayinclude air, glass, vacuum, plastics, and a fiber optic line, amongothers.

Shown in FIG. 1, the wall 21 encloses a process environment 20. The wall21 environmentally seals the process environment from an outsideenvironment. In FIGS. 1-3, the outside environment is recognized as thatwhich is external to the process barrier 21.

A process operation 25, located within the process environment 20,performs a function using the received laser energy 35. Illustratively,in one embodiment, a vacuum 20 exerts a negative pressure on the barrier21 as the process operation 25 receives high-powered laser energy 35 formechanically inspecting a system. In another exemplary embodiment, thewall 21 may define a pressure vessel so that a process operation 25receives high-powered laser energy 35 for manufacturing-relatedapplications. It should be added that a process interface 23 may beprovided by the process environment 20 to facilitate reception and/ortransmission of high-powered laser energy 35 for use with the processoperation 25.

In one exemplary embodiment, the process operation 25 receives thelasing energy 35 in a range between 10 and 200 watts. In anotherembodiment, lasing energy is received by the lasing system 15 in a rangebetween 200 to about 1400 watts. In yet another exemplary embodiment,the lasing energy 35 may be sent through the line 30 in a range between1400 to about 10000 watts.

As shown in FIG. 1 and FIG. 2, the lasing connection system 15 includesa mounter 60 and a connector 80. The lasing connection system 15 and thewall 21 operate to form an environmental seal between the processenvironment 20 and the outside environment. In FIG. 1, the mounter 60 iscoupled to the process wall 21. The mounter 60 has a means for couplingto the process environment 20. The mounter 60 may include a mountingpassageway 61 for the transmission of energy 35 from a laser to theprocess environment 20.

Shown in FIG. 1 and FIG. 3, the connector 80 is coupled to the mounter60 and the line 30. The connector 80 receives the energy 35 from theline 30 and directs the energy to the process environment 20.

A sealer 50 is coupled to the connector 80 and the mounter 60. Thesealer 50 isolates the process environment 20 to an externalenvironment. The sealer 50 includes a sealing body 51. In one exemplaryembodiment, as shown in FIG. 2, the sealing body 51 defines a sealingchannel 58. In operation, the connector 80 is in sealed contact with thesealing channel 58. A sealed contact isolates the process environment toan external environment. One example, among others, of a sealed contactbetween the sealed channel 58 and the connector 80 is a braze weld.

The sealing body 51 can includes a sealing face 52. To form anenvironmental barrier between the process environment and the outsideenvironment, the sealing face 52 is positioned against the mounter 60.Moreover, the sealer 50 may include at least one system seal 55. Thesystem seal 55 is disposed between the sealing body 51 and the mounter60 to establish a barrier for isolating the process environment.

As shown in FIGS. 1-2, an interface connection 70 receives the sealingbody 51. The interface connection 70 is coupled to the wall 21.Accordingly, for the exemplary embodiments of FIGS. 1-3, the sealingbody 51 joins with the mounter 60 via the interface connection 70.

In one embodiment, a laser connector connection unit 40 is releasablefrom coupling with the wall 21 of the process environment 20.Particularly, the connector 80 of the laser connection unit 40 isreleasably coupled to the mounter 60 and the line 30. The interfaceconnection 70 may be releasable from the mounter 60. The sealer 50 maybe releasable from the interface connection 70. The mounter 60 in oneexemplary embodiment is releasable from the wall 21. Releasably couplingconnector 80 to mounter 60 involves securing the connector to themounter with a mechanical connection operable to mechanically engage anddisengage in a controlled manner (i.e. designed to be released).

In general, as shown in FIGS. 1-3, lasing in a process environment 20operatively includes generating laser energy 35 from a high-poweredlaser (not shown). The laser energy 35 is transmitted through a line 30to a lasing system 15. The lasing system 15 includes a laser connectionunit 40 and a wall 21 enclosing the process environment 20. The laserconnection unit 40 and the wall 21 thus form an environmental barrierbetween the process environment 20 and an outside environment 29.

Alternatively, one exemplary embodiment provides linking a processenvironment 20 to a lasing system 15 through a line 30. As such, theline 30 is placed in a connector line interface 82 provided by theconnector 80. The line 30 passes through the connector line interface 82through a connector 80.

The line 30 passes through the connector 80 from the connector lineinterface 82 through a connector shell 85 to a feeder line 89 positionedwithin the process environment 20. Ultimately, the feeder line 89 iscoupled to the process operation 25 to deliver lasing energy thereto. Torelieve the line 30 of mechanical strain, the line is set within strainrelief material 86 of a type well known in the industry, such as forexample rubber. It should be also added that shell potting 87 isprovided to mechanically affix the laser energy transmission line 30 tothe connector shell 85 as well as to provide an environmental seal.

As is typical in the high-powered laser industry, the connector 80 isprimarily composed of metallic materials. Some examples of high-poweredlaser connections are the losch LD 80 by Richard Losch, Inc. of Bend,Oreg. and Pave-Optic Seal by Pave Technology Company of Dayton, Ohio.

Continuing with the exemplary embodiment, the connector 80 couples to amounting flange 60. The mounting flange 60 includes a passageway 61 forthe transmission of high-powered laser energy 35 from the line anddirects the energy to the process environment 20. A sealing assembly 50seals the interface between the connector 80 and the mounter 60.

FIG. 3 is another schematic diagram detailing an embodiment of theinvention of FIG. 1 and FIG. 2, whereby a laser connection system 15 ispositioned against and intersects with the barrier 21. As such, theconnection interface 82 is sheltered within the mounter 60 to protectthe juncture of the connection interface 82 with the line 30.Accordingly, the barrier 21 and the laser connection unit 40 form asealed barrier for isolating the process environment 20. Accordingly, asealing assembly 50 forms an environmental baffler between the processenvironment and an external environment.

As such, a system for coupling energy from a high-powered laser to aprocess operation within a process environment is described.Additionally, a releasable connection system for engagement to a wallenclosing a process environment and receiving high-powered laserenergies is described. In view of the above detailed description of thepresent invention and associated drawings, other modifications andvariations will now become apparent to those skilled in the art. Itshould also be apparent that such other modifications and variationsmight be effected without departing from the spirit and scope of thepresent invention as set forth in the claims that follow.

1. A lasing system, the lasing system receiving laser energy from aline, the lasing system comprising: a wall enclosing a processenvironment; the wall environmentally sealing the process environmentfrom an outside environment; a process operation, located in the processenvironment; the process operation performing a function using thereceived laser energy; a laser connector, releasably coupled to the lineand to the wall; and a system seal positioned between the wall and thelaser connector to form an environmental barrier between the processenvironment and the outside environment.
 2. The lasing system accordingto claim 1 wherein the energy from the laser is between 200 to about1400 watts.
 3. A coupling arrangement that allows a laser beams to beintroduced into a closed chamber comprising: a laser connector opticallycoupled to a laser source; a mounting system having an interiorpassageway for transmitting energy from said laser source wherein saidmounting system mounts on an outer boundary of said closed chamber; andan interface that joins said laser connector to said mounting systemwhile providing an environmental barrier between an interior of saidclosed chamber and said external environment; a system seal positionedbetween a sealing body and said mounting system forms an environmentalbarrier.
 4. The coupling arrangement of claim 3, wherein said lasersource couples to said laser connector via an optical channel thatcomprises air, glass, vacuum, plastic, gas or fiber channels.
 5. Thecoupling arrangement of claim 3, wherein said mounting system directslaser energy from said laser source to a process environment within theclosed chamber.
 6. The coupling arrangement of claim 3, wherein saidinterface comprises an environmental seal or barrier.
 7. The couplingarrangement of claim 3, wherein said laser source is releasably coupledto said mounting system.
 8. The coupling arrangement of claim 3, whereinsaid interface releasably joins to said laser connector to said mountingsystem.
 9. The coupling arrangement of claim 3, wherein pottingmechanically affixes a transmission channel to said laser connector. 10.The coupling arrangement of claim 3, wherein said mounting systemcomprises a mounting flange.
 11. The coupling arrangement of claim 3,wherein said interface comprises a sealing assembly.
 12. The couplingarrangement of claim 3, wherein said laser source has an energy between200 and 10,000 watts.